Dheeraj Inavolu

Experience

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  Ve Commercial Vehicles Limited( A Jv Between Eicher & Volvo Limited)

  Mar 2018 - Jul 2018

  Manufacturing and Quality Intern

  • Conducted Lean analysis using process flow mapping, identified causes of wastes using Fishbone diagram and 4Ms in assembly.• Assisted NPI engineer to check product standards using Audit checklists, Gauge R&R studies and GD&T.• Executed SMED and RPW line balancing technique to reengineer the layout of the sub-assemblies.• Controlled the sub-assembly flow using SPC, Run charts, eliminated the NVS and improved line efficiency by 26%.• Identified muffler-related faults using Kaizen event, examined productivity loss using OEE, and conducted a 5-Why study to eliminate the defects. Show less

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  Goa Shipyard Limited In Vasco De Gama

  Mar 2019 - Jul 2019

  Process Engineering Intern

  • Utilized Control Charts such as X-bar and R, Cp/Cpk to accurately estimate process variability in shipbuilding outfitting.• Evaluated the Value stream mapping to eliminate process waste using 5S and improved production efficiency by 20%.• Adopted PFMEA to identify the process failure modes, Root Cause Analysis to identify the time-consuming fixture.• Re-Designed the fixture for holding the shaft using Creo by discovered the critical stress points. Reduced installation time by 10%, subsequently reduced the launch time by 8%. Show less

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  4GR-For a Good Reason

  Jul 2020 - Nov 2022

  Coordinator

  Actively undertaken the responsibility of locating and providing refuge for both abandoned individuals and vulnerable animals. Through strategic collaborations with various organizations, I have effectively orchestrated fundraising initiatives geared towards addressing their essential needs and medical requirements. My dedicated efforts in this capacity reflect a commitment to fostering the welfare of the marginalized, and I continue to drive impactful change by merging empathy with practical solutions. Show less

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  Inavolu Industries Ltd

  Aug 2020 - Dec 2021

  Supply Chain and Operations Manager

  • Introduced ERP and barcode scanning technology in the industries to manage inventory and stock control.• Monitored and controlled various process using Kaizen event and Fishbone diagram resulting in reduction of non-conformingparts by 20% and improved efficiency by 33%.• Facilitated 5S to standardize workplace, TPM for improved equipment maintenance and effectiveness.• Eliminated recurrence of a defect by using RCA and Poka-Yoke concept in the cement poles manufacturing industry.• Assisted in designing the inventory and developing the procurement plans to maximize service level objectives at lowest cost,resulting in cost savings of approximately $2M.• Incorporated new inspection techniques such as visual, dimensional and FMEA analysis for finished goods to ensure compliancewith quality standards, resulting in 25% decrease in defective products and improved supplier relationships. Show less

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  Texas A&M University

  Sept 2022 - May 2023

  Graduate Teaching Assistant

  - Supporting educational activities, facilitating discussions, and providing guidance to students.- Assisted in curriculum development, including creating instructional materials, assignments, and assessments to enhance the learning experience.- Engaged proactively with both students and faculty, contributing to a collaborative and dynamic academic environment while honing my own teaching and communication skills.

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  ZT Systems

  Jun 2023 - now

  Server Build- Improved first-pass yield by 20% by resolving label and torque issues during server assembly setup.- Standardized SOPs, QMS, and training for new manufacturing processes, ensuring compliance and efficiency.- Reduced downtime by 89% and defects by 95% using Lean Six Sigma tools to optimize build processes.- Reduced Test Cell Occupancy (TCO) by 6 hours per rack through SCM card and Y-cable flashing stations.- Scaled production by increasing throughput from 2 racks to 40 racks per day, improving order fulfillment.- Enhanced OEE by analyzing data, resolving supply-demand imbalances, and aligning operations with goals.New Product Transfer- Led new server launches, managing NUDD analysis, BOM comparisons, and material readiness for smooth transitions.- Coordinated FAI and pilot builds, ensuring on-time shipment approvals through cross-functional team alignment.- Developed project plans for product qualifications, tracking milestones, material availability, and build readiness.- Established communication protocols to address DFM issues, reducing iteration cycles and improving build success rates.- Standardized pilot build workflows, creating checklists and training materials, reducing cycle times by 25%.- Optimized supply-demand balancing with procurement, maintaining 95% material readiness for build phases.- Drove alignment on BOM accuracy and ECOs, minimizing disruptions during new build introductions. - Conducted factory audits, addressed equipment gaps, and facilitated weekly updates to ensure clear communication and early certification.Factory Expansion- Redesigned facility layout with Revit, reducing material handling by 30% and streamlining process flow.- Developed project timelines for factory setup, presenting readiness and addressing risks in MRR meetings.- Managed Capex and financial models to secure factory investment approvals, while overseeing procurement for timely resource acquisition. Show less Manufacturing/New Product Introduction/Business Intelligence▪ Reduced cycle time by 8% and error rate by 25% through Process Flow Analysis, Time Studies, and Value Stream Mapping; implemented Lean Six Sigma principles for improved workflow and efficiency.▪ Optimized EOL layout and workspace organization using Autodesk Revit and 6S methodology, reclaiming 4,426 sq. ft of non-utilized space for $138K in annual savings, and reduced bottleneck time by 10.1 minutes per rack.▪ Leveraged Visio to optimize the SCM card update layout, enhancing operator ergonomics and boosting flow efficiency by 12% before server assembly.▪ Streamlined single server EOL process by conducting Gap Analysis, enhanced visual coordination by implementing traveler document to show tracking steps from manufacturing to EOL stages.▪ Established Hi-Pot station and optimized test setup using DOE; documented SOPs and results in Confluence for ongoing process development.▪ Enforced mandatory SFC scan tracking by introducing a new process and collaborating with customer and product operation teamsto ensure all scan fields were validated, thereby preventing label printing issues.▪ Designed port covers for various GPU products using SOLIDWORKS, minimizing risks during unpacking and assembly by 14% and improving protection throughout the server assembly process.New Product Introduction/Business Intelligence▪ Standardized Power Metering in NPI using DMAIC and SOPs, established a management system for smooth data collection, and developed an Excel template for data transformation to support server testing capacity studies.▪ Automated data management by developing an ETL process with Excel macros, loading power draw data into a database, and creating a Tableau dashboard for real-time analysis.▪ Developed and deployed a NPT label management system to standardize real-time requests, minimizing downtime on the production line by 96% through consistent server label management. Show less

  • Sr. Functional Technical Project Manager

    Jan 2025 - now

  • Sr. Manufacturing Engineer

    Jan 2024 - Feb 2025

  • Manufacturing Engineering Intern

    Jun 2023 - Jan 2024